Method and apparatus for the formation of hydrophobic surfaces

ABSTRACT

The invention relates to the application of a coating to a substrate in which the coating includes a polymer material and the coating is selectively fluorinated and/or cured to improve the liquid repellance of the same. The invention also provides for the selective fluorination and/or curing of selected areas of the coating thus, when completed, providing a coating which has regions of improved liquid repellance with respect to the remaining regions and which remaining regions may be utilized as liquid collection areas.

FIELD OF INVENTION

The invention to which this application relates is to a method ofapplying a coating to a surface of a substrate or article, apparatus forthe application of said coating, and the completed substrate or articlethemselves, said coating having a liquid repellent characteristic of animproved nature with regard to the prior art which is herein defined.

In particular, although not necessarily exclusively, the coating towhich the invention applies includes a crosslinked fluoropolymermaterial.

BACKGROUND OF THE INVENTION

Coatings of this type can have a wide range of uses and the substrate towhich the same is applied can be solid surfaces such as metal, glass,ceramics, semiconductors, flexible surfaces such as paper, textilesand/or polymers and the like and indeed any surface which is capable ofsupporting and retaining the coating thereon. The coating can becontrolled to be either generally repellent to all liquids orspecifically repellent of particular liquids to suit particularpurposes.

The extent or degree of the liquid repellency is known to be a functionof the number of fluorocarbon moieties that can be generated and locatedwith respect to the available surface area and also a function of thesurface roughness characteristics. In general, the greater theconcentration of fluorocarbon moieties and the greater the degree ofsurface roughness then the greater the repellent characteristic of thecoating.

Conventionally a coating of the type of interest in this patent isapplied to the surface of a substrate by any of sputter deposition ofmaterial from a polytetrafluorethylene (PTFE) target, exposure to F₂ gasor using plasma techniques including exposure to fluorine-containingelectrical discharges and/or plasma polymerisation of fluorocarbonmonomers.

The known technique most often used is the plasma technique which isrecognised as being clean, dry, and generating little waste materialcompared to the conventional wet chemical methods. A plasma is generatedfrom molecules which are subjected to ionising electrical fields and,when completed, and performed in the presence of the substrate, theions, radicals and excited molecules in the plasma react directly withthe substrate or polymerise in the gas phase and react with growingpolymer films on the substrate to form the coating thereon.

As stated, it is also known to improve the repellence of the coating bycontrolling the surface roughness. One method of increasing the surfaceroughness is to first apply to the surface of the substrate, anintermediate layer of material which has a surface roughness greaterthan that of the surface of the substrate. The provision of thisintermediate layer is described by the Cassie-Baxter equation wheresurface roughness causes air to be trapped in a void which prevents theliquid from penetrating the surface hence increasing the repellencecharacteristic of the coating.

The trapping of the air in voids minimises the contact angle hysteresisand results in the provision of what are known as “super hydrophobic”coatings upon which a liquid drop spontaneously or easily move acrossthe substrate coating even in horizontal or substantially horizontalplanes.

The provision of intermediate layers applied to the substrate surface toimprove the surface roughness are normally achieved by any or anycombination of the following:

Sublimation of aluminium acetylacetonate from a boehmite, titania orsilica coating,

Sol-gel deposition of alumina and silica,

Anodic oxidation of aluminium,

Photolithographically etched surfaces.

All of the above processes include a pre-roughening step followed by areaction of the fluorine containing coupling agent to impart low surfaceenergy.

The aim of the present invention is to provide a method, apparatus andfinished article which represent, respectively, improvements withrespect to the repellency of the coating applied thereby and onto thesubstrate surface. It is also an aim to provide the coating in a mannerwhich has the required repellency, is durable and therefore can becommercially exploited.

SUMMARY OF THE INVENTION

In a first aspect of the invention there is provided a method forapplying a coating to a surface of a substrate, said method comprisingthe steps of applying a polymer material to the said substrate surface,fluorinating the surface of said polymer material on the substrateand/or curing at least part of the said coating.

Typically, the polymer material can be applied in any conventionalmanner to suit particular method requirements and, for example, caninclude application by spin coating, solvent casting, dipping, spraying,plasma deposition, atomisation or chemical vapour deposition.

The polymer material can comprise a number of components, including butnot limited to, homopolymers and copolymers. These polymeric componentsmay occur singly, in combination with one another, or in the presence ofnon-polymeric additives. The components of polymer blends may bemiscible or immiscible.

In one embodiment, the polymer material includes unsaturated bonds and,as an example, two such polymers are polybutadiene or polyisoprene.

In one embodiment the cover polymer material is a blend where only onecomponent of the blend is crosslinkable, e.g. for a two component blendsystem (e.g. polybutadiene+polystyrene), fluorination and curing isfollowed by solvent washing to leave behind domains of the hydrophobiccrosslinkable component, in this case polybutadiene. The fluorinatedpolystyrene component is washed out due to it not being capable ofundergoing crosslinking.

Typically, the polymer coating forms at least the outer surface of thecoating applied to the substrate. In one embodiment, the polymer coatingforms part of the coating applied to the substrate surface. Thus, forexample, the coating applied to the substrate surface can comprise aseries of layers, with the outer layer, i.e. that furthest removed fromthe substrate surface, being of the polymer material and more typicallya polymer including unsaturated bonds. The remainder of the layers ofthe coating can be made up of any combination of materials such as, forexample, polymer material with saturated bonds.

In a further aspect of the invention a polymer material, typicallyincluding unsaturated bonds, forms only part of the outer surface of thecoating. Thus, for example, the outermost surface of the coating cancomprise domains or patterns of polymer material containing unsaturatedbonds, surrounded by areas consisting of a non-polymeric material or adifferent polymer material, (typically one including no unsaturatedbonds). Examples of such multi-component surfaces are those created bysections of composites or laminates and the segregation of componentswithin copolymers and blends of polymers and/or copolymers. In additionthe coating may comprise additional layers, supplementary to theoutermost surface layer, which can consist of any combination ofmaterials.

The fluorination of the coating can be achieved by selective exposure ofthe same to atomic, molecular or ionic fluorine containing species.

In one embodiment, plasma is used to generate fluorinating species. Thecoated substrate may be disposed within the plasma, ox exposed tofluorinating species created by a remotely located plasma.

Suitable plasmas for use in the method of the invention includenon-equilibrium plasmas such as those generated by radio frequency (RF),microwaves and/ox direct current. The plasma may be applied in a pulsedmanner or as a continuous wave plasma. Typically the plasmas can beoperated at any or any combination of low pressure, atmospheric orsub-atmospheric pressures to suit particular purposes and reference toplasma herein should be interpreted as including any of these plasmaforms.

Typically, the plasma either comprises the fluorinated compound alone orin a mixture with, for example, an inert gas. In one embodiment thefluorinated compound is introduced into the plasma treatment chambercontinuously or in a pulsed manner by way of, for example, a gas pulsingvalve. In one embodiment, the compound used for generating the fluorinecontaining plasma is SF₆ or compounds of formula CH_(x)F_(4-x) where xhas integer values from 0 to 3.

The step of curing the fluorinated surface affects the crosslinking ofthe unmodified, unsaturated polymer below the fluorinated surface andthe degree of fluorination and roughened surface morphology imparted bythe fluorination are largely unaffected by this process so that thecoating retains its repellent characteristics whilst improving in termsof mechanical durability.

Typically, the method of curing used can be any or any combination of,heating, VUV radiation, UV radiation, electron beam irradiation orexposure to any other ionising radiations.

In one embodiment the fluorination and/or curing step can be achieved bythe control or ramping of the temperature of the polymer film during thefluorination procedure, in which case the fluorination occurs at thelower temperature range and, as the temperature increases, curingoccurs.

In a further aspect of the invention there is provided a method forapplying a coating having liquid repellent characteristics to a surfaceof a substrate, said method comprising the steps of applying a coatingto the substrate surface, said coating having at least an outer layer ofa polymer including unsaturated bonds, said polymer being fluorinatedand cured and wherein the fluorination and/or curing is performed on thepolymer material in a selected pattern so as to provide selectivelyfluorinated and/or cured portions and selectively unfluorinated and/oruncured portions of said coating.

In one embodiment the selection can be to completely fluorinate and curethe polymer material of the coating.

Alternatively, in one embodiment, the selected pattern of fluorinationand/or curing on the substrate surface coating is achieved with the useof a spatially resolved means of curing or fluorination such as an ionbeam, electron beam, or laser or via masking which matches and assiststhe selective pattern of fluorination or curing required.

In one embodiment the mask includes a series of apertures, saidapertures, when said mask is placed over the said substrate surfacecoating, defining the areas of said coating which are to be fluorinatedand/or cured.

It should therefore be appreciated that the method can comprise thesteps of applying the coating, selectively fluorinating parts of thecoating and curing all of the coating thereafter or alternativelyapplying the coating, fluorinating the entire coating and thenselectively curing said coating.

In one embodiment, UV irradiative curing is effected in a selectedpattern through use of a photo mask. The pattern of transmitting anopaque material upon the mask thereby being transferred to thefluorinated coating as a pattern of cured and uncured areas. As curingis accompanied by densification, the cured areas of the fluorinatedcoating are lower in height than the uncured areas and this heightcontrast allows the formation of surface structures such as channels andpockets for the movement and containment of liquids and aerosolparticles, such as and including polymer solutions, salts dissolved inliquid, and other liquid based systems whereupon removal of the liquidleaves solid behind.

In a further aspect of the invention there is provided apparatus for thegeneration of a coating for a substrate surface, said apparatuscomprising means for application of a coating to a surface of asubstrate, said means including means for applying a polymer containingunsaturated bonds to form at least the outer surface of the coating,fluorination means for fluorinating the said outer surface of saidcoating and curing means for curing said outer surface of the coating.

In one embodiment, the apparatus includes at least one masking means forplacement with respect to the coating prior to fluorination and duringthe fluorination, said mask is formed so as to allow the selectivefluorination of exposed portions of said coating.

In a further embodiment, there is provided a masking means for placementwith respect to the coating during the curing of the coating to allowselected curing of portions of said coating.

In one embodiment, the pattern of fluorination achieved by the maskingmeans is matched with the pattern of curing by the curing masking meansto allow the provision of selected portions of the coating which arefluorinated and cured.

In a further aspect of the invention there is provided a substratehaving at least one surface to which a coating is applied, said coatinghaving at least an outer layer of polymer material and at least aportion of said polymer material is fluorinated and cured to provide thesame with improved liquid repellent and durability characteristics.

In one embodiment selective portions of the polymer material have saidliquid repellent characteristics, said portions defining areas which arenot fluorinated and/or cured and which can act as collecting areas forliquid. In one embodiment said coating has defined therein a number ofspaced liquid collection areas, each separated by areas of increasedliquid repellence. In one embodiment the substrate can be used as aliquid sample collection means.

BRIEF DESCRIPTION OF THE DRAWINGS

Specific embodiments of the invention axe now described with referenceto the accompanying drawings; wherein.

FIG. 1 is a graph showing the surface elemental composition of 4.5 μmthick polybutadiene films which have been plasma fluorinated for 5minutes at various RF power levels;

FIG. 2 is a graph showing the RMS roughness of 4.5 μm thickpolybutadiene films which have been plasma fluorinated for 5 minutes atvarious RF power levels;

FIG. 3 is a graph showing the water contact angle of 4.5 μm thickpolybutadiene films which have been plasma fluorinated for 5 minutes atvarious RF power levels;

FIG. 4 illustrates a further embodiment of the invention and an infrared spectra of plasma fluorinated polybutadiene (60 W, 10 min) as afunction of UV exposure time of a nonpatterned surface;

FIG. 5 illustrates the embodiment of FIG. 4 showing a series of AFMheight images of a UV patterned surface;

FIG. 6 illustrates the embodiment of FIG. 4 showing a series of opticalmicroscope images showing microfluidic self organisation of waterdroplets on patterned 236 nm thick polybutadiene film;

FIG. 7 illustrates the embodiment of FIG. 4 showing optical microscopeimages of crystals grown on patterned polybutadiene film as a functionof exposure time to nebulized mist;

FIG. 8 illustrates further optical microscope images of polystyrenebeads deposited into patterned polybutadiene;

and FIG. 9 illustrates the embodiment of FIG. 4 with a patterned surfaceshowing the Raman analysis of the patterned polybutadiene film.

DETAILED DESCRIPTION OF THE INVENTION

In a first illustrative example, Polybutadiene (Aldrich, M_(w)=420,000,36% cis 1.4 addition, 55% trans 1.4 addition, 9% 1.2 addition) isdissolved in toluene (BDH, +99.5% purity) and spin coated onto siliconwafers using a photoresist spinner (Cammax Precima) operating at speedsbetween 1500-4500 rpm. The applied coatings axe subsequently annealed at90° C. under vacuum for 1 hour in order to remove entrapped solvent.

In accordance with the method of the invention, fluorination of thecoating is, in this example, performed in a cylindrical glass, plasmareactor of 5 cm diameter, 470 cm³ volume, base pressure of 4×10⁻³ mbar,and with a leak rate of better than 6×10⁻⁹ mol s⁻¹.

The reactor vessel is connected by way of a needle valve to a cylinderof carbon tetrafluoride (CF₄) (Air Products, 99.7% purity).

A thermocouple pressure gauge is connected by way of a Young's tap tothe reactor vessel. A further Young's tap is connected with an airsupply and a third leads to an E2M2 two stage Edwards rotary pump by wayof a liquid nitrogen cold trap. All connections are grease free.

An L-C matching unit and a power meter are used to minimise the standingwave ratio (SWR) of the power transmitted from a 13.56 MHz R.F.generator to a copper coil wound around the reactor vessel wall.

In order to carry out the fluorination of the unsaturated, polybutadienecoating the reactor vessel is scrubbed with detergent, rinsed withpropan-2-ol, oven dried and then further cleaned with a 50 W air plasmafor 30 min. Next, the reactor is vented to air and a polybutadienecoated silicon wafer placed into the centre of the chamber defined bythe reactor vessel on a glass plate. The chamber is then evacuated backdown to base pressure (4×10⁻³ mbar).

Carbon tetrafluoride gas is admitted into the reaction chamber via aneedle valve at a constant pressure of 0.2 mbar and allowed to purge theplasma reactor followed by ignition of the radiofrequency glowdischarge. Typically 5-10 minutes is found to be sufficient to givecomplete surface fluorination of the polybutadiene coating. After thisthe RF power generator is switched off and carbon tetrafluoride gasallowed to pass over the sample for a further 5 minutes beforeevacuating the chamber back down to base pressure, and finally ventingto air.

Curing of the fluorinated polybutadiene films is carried out by placingthem in an oven, in an atmosphere of air, at 150° C.

Analysis of the coatings is achieved by using several complementarytechniques. X-ray photoelectron spectroscopy (XPS) is used to obtain theelemental composition of the surfaces, and to identify variousfluorinated species by means of deconvoluting the C(1s) spectra. Inaddition to XPS, FT-IR is used to obtain information on chemical groupspresent within the coating (Perkin Elmer, Spectrum One).

The thickness of the polybutadiene films is measured using aspectrophotometer (Aquila Instruments, nkd-6000).

The coatings are imaged by Atomic Force Microscopy (AFM) (DigitalInstruments, Nanoscope III). RMS roughness values are calculated over 50nm×50 nm scan areas.

The super-hydrophobicity and oleophobicity of the coatings axeinvestigated by sessile drop contact-angle measurements carried out at20° C. with a video capture apparatus (A.S.T. Products VCA2500XE). Theprobe liquids used are high purity water (B.S. 3978 Grade 1) todetermine hydrophobicity and a variety of linear chain alkanes(hexadecane, tetradecane, dodecane, decane, and octane, +99% purity,Aldrich) to evaluate oleophobicity. In the case of super-hydrophobicsurfaces, the water droplets are kept stationary by the dispensingsyringe. Advancing and receding contact angle values are obtained byincreasing or decreasing the liquid drop volume at the surface.

The increase in coating durability after curing is ascertained byNanoindentation hardness testing, before and after crosslinking, with aNano instruments Nano II machine equipped with a Berkovich indenter.

The experiments carried out use average RF powers in the range of from 5to 80 W. The results of the XPS analysis of 4.5 μm thick polybutadienefilms plasma fluorinated for 5 minutes at various powers are shown inFIG. 1.

In FIG. 1 it can be seen that plasma fluorination caused theincorporation of a large amount of fluorine into the surface of thepolybutadiene coating. Deconvolution of the C(1s) spectra shows that CF,CF₂ and CF₃ environments are present.

FIG. 2 shows the RMS roughness, measured using AFM, of 4.5 μm thickpolybutadiene films which have been plasma fluorinated for 5 minutes atvarious power levels.

It can be seen that the plasma fluorination results in an overallincrease in the roughness of the polybutadiene coating. RF power levelsbelow 30 W result in large undulating features. An increase in the RFpower results in a diminishment of these features and their replacementwith finer scale roughness. The transition between the two differentmorphologies is responsible for the decrease in RMS roughness at RFpowers of approximately 30 W.

The effect of the incorporation of fluorine and the simultaneousincrease in RMS roughness upon the water repellency of 4.5 μm thickpolybutadiene films which are plasma fluorinated for 5 minutes atvarious powers is shown in FIG. 3.

Plasma fluorination is therefore shown to cause a large increase in thehydrophobicity of the coating. Water contact angles exceed 157° for RFpowers of above 40 W. More accurate measurement is not possible as thedroplets quickly rolled off the coating, that is the surfaces displayedsuper-hydrophobic behaviour.

The oleophobicity of the fluorinated coatings is shown by contact anglemeasurements with droplets of linear chain alkanes given in Table 1. The4.5 μm thick polybutadiene coating illustrated has been plasmafluorinated at an RF power of 60 W for 10 minutes.

TABLE 1 PROBE CONTACT ANGLE/° LIQUID Equilibrium Advancing RecedingHysteresis Water 174.9 ± 0.4 173.1 ± 0.4 172.7 ± 0.5  0.4 ± 0.4Hexadecane 118.7 ± 0.8 119.1 ± 1.0  30.1 ± 1.7   89 ± 2.0 Tetradecane  109 ± 0.9 110.8 ± 1.2  29.8 ± 1.3   81 ± 1.8 Dodecane  98.4 ± 0.9100.2 ± 1.1  29.5 ± 1.9 70.7 ± 2.2 Decane  89.8 ± 1.5  92.9 ± 1.1  29.7± 1.0 63.2 ± 1.5 Octane  65.2 ± 0.8  67.4 ± 0.9   28.5 ± 1.0 i 38.9 ±1.3

The low hysteresis observed when using water as a probe liquid confirmsthat the coating is super-hydrophobic. In addition it can be seen thatthe coating is oleophobic towards a range of oils. However the largehysteresis observed with alkane probe liquids, attributable to theirlower surface tensions' enabling them to wick into surface pores, showsthat the coating is not super-oleophobic.

After fluorination the coatings are thermally cured at 155° C. Theeffect of curing for 1 hour upon the repellency, roughness and surfacecomposition of a 4.5 μm thick polybutadiene coating plasma fluorinatedat a RF power of 60 W for 10 minutes is shown in Table 2.

TABLE 2 Measurement Uncured Cured Water contact angle 174.9 ± 0.4° 173.8± 0.5° Decane contact angle 89.8 ± 1.5° 76.4 ± 2° XPS % F 70 ± 2 69 ± 2XPS % C 30 ± 2 29 ± 2 XPS % O 0 ± 0 2 ± 2 AFM roughness 193 ± 5 nm 191 ±5 nm ARMS

It can be seen that curing does not significantly affect thesuperhydrophobicity and RMS roughness of the coating. The slightdecrease in oleophobicity is attributed to the incorporation of a smallamount of oxygen.

The affect of curing upon surface durability is shown in Table 3. A 4.5μm thick polybutadiene coating plasma fluorinated at a RF power of 60 Wfor 10 minutes was cured for 48 hours at 155° C.

TABLE 3 Material Hardness/Mpa Uncured fluorinated of butadiene  8 ± 1Cured fluorinated polybutadiene 64 ± 8

It can be seen that curing results in an eight-fold increase in coatinghardness over the uncured fluorinated material.

The results of this illustrative example therefore illustrate theadvantageous benefits which can be obtained by the method andutilisation of apparatus of the present invention. The results relate tothe fluorination and curing over the entire surface of a substrate forease of testing.

However as previously discussed a further aspect of the invention is theprovision of the fluorination and/or curing over selected portions ofany given surface. The ability to selectively fluorinate and cureparticular surfaces provides the ability to design articles for specificuses and for the surfaces to have the required characteristics inrequired areas. One possible use is to define portions of the surfacewhich are not fluorinated or cured and which act as collection areas forliquids applied to the surface and which liquid is repelled from thoseportions which are fluorinated and cured and which typically surroundand define the liquid collection areas. Thus, in use, the liquid held ineach liquid collection area can define a sample to be tested. The saidtreated and non-treated portions are typically defined during thetreatment process by the provision of masking means and/or selectiveprinting which can be positioned relative to the surface.

A specific embodiment of this selective or patterned treatment method isnow described with reference to FIGS. 4-9. In this example, there isdescribed a two-step approach for fabricating spatially ordered arraysof micron size particles and also metal salts by exposing patternedsuper-hydrophobic surfaces to a nebulized mist of the desired species.This entails plasmachemical fluorination of polybutadiene thin filmsurfaces followed by spatially localised UV curing by crosslinking andoxygenation.

CF₄ plasma fluorination of coating is carried out in a cylindrical glassreactor (5 cm diameter, 470 cm³ volume) connected to a two stage rotarypump via a liquid nitrogen cold trap (base pressure of 4×10⁻³ mbar, anda leak rate of better than 6×10⁻⁹ mol s⁻¹). An L-C matching unit is usedto minimise the standing wave ratio (SWR) of the power transmitted froma 13.56 MHz R.F. generator to a copper coil externally wound around theglass reactor. Prior to each plasma treatment, the chamber is scrubbedwith detergent, rinsed in propan-2-ol, and then further cleaned using a0.2 mbar air plasma operating at 50 W for 30 min. A piece ofpolybutadiene coated substrate is then placed into the centre of thereactor, followed by evacuation to base pressure. Nex CF₄ gas (99.7%purity, Air Products) is admitted into the system via a needle valve ata pressure of 0.2 mbar, and after 5 min of purging, the electricaldischarge is ignited. Upon completion of plasma exposure, the system isevacuated, and then vented to atmosphere.

Patterning of the fluorinated polybutadiene film surfaces entails UVirradiation (Oriel low pressure Hg—Xe arc lamp operating at 50 W,emitting a strong line spectrum in the 240-600 nm wavelength region)through a copper grid photomask (1-000 mesh, Agar Scientific')positioned just above the polymer surface.

These micro-patterned films are exposed to a nebulized aqueous mist(Inspiron nebulizer operating with a nitrogen gas flow of 3 dm³ min⁻¹)of either Cu₂SO₄ salt solution (0.00125 M, Aldrich) or polystyrene beads(1×10⁹ beads per ml). In the case of gold (III) chloride (Aldrich 99%),the patterned film is dipped into a 10% w/v ethyl acetate (Fisher 99%)solution for 10 min followed by rinsing in methanol to dislodgeextraneous AuCl₃ species.

XPS surface analysis is undertaken on a VG ESCALAB MkII spectrometerequipped with an unmonochromatised Mg K_(α) X-ray source (1253.6 eV) anda hemispherical analyser. Photoemitted core level electrons arecollected at a fixed takeoff angle (75° away from the sample surface)with electron detection in constant analyser energy (CAE) mode operatingat 20 eV pass energy. Elemental sensitivity (multiplication) factors aretaken as being C(1s) F(1s): O(1s) equals 1.00:0.35:0.45. No spectraldeterioration due to X-ray radiation damage was observed during the timescale associated with data acquisition.

Infrared analysis of polybutadiene films coated onto polished potassiumbromide disks is carried out on a Perkin Elmer Spectrum One FTIRinstrument operating in transmission mode at 4 cm⁻¹ resolution inconjunction with a DTGS detector.

Sessile drop contact angle measurements are undertaken at 20° C. with avideo capture apparatus (A.S.T, Products VCA2500XE) using high puritywater as the probe liquid (B.S.3978 Grade 1). In the case ofsuper-hydrophobic surfaces, the water droplets are kept stationary bythe dispensing syringe. Advancing and receding contact anglemeasurements are made by increasing or decreasing the liquid drop volumewhilst on the surface.

AFM images of the patterned surfaces are acquired using a DigitalInstruments Nanoscope III scanning probe microscope. Damage to the tipand substrate was minimised by operating in Tapping Mode ARM.Corresponding optical images are captured with an Olympus BX40microscope.

Raman spectroscopy and spatial mapping is performed on a Dilor Labrammicroscope equipped with a 1800 lines mm⁻¹ diffraction grating and ahelium-neon laser excitation source (632.8 nm line operating at 11 mW).

(a) UV Irradiation of Fluorinated Polybutadiene Films

XPS analysis detected a small amount of oxygen incorporation (2%) at thesurface following UV irradiation of the whole plasma fluorinated polymerfilm (no mask), Table 4.

TABLE 4 XPS analysis of CF₄ plasma fluorinated 236 nm thickpolybutadiene film (60 W, 10 min) prior to and following UV exposure.Substrate % C % O % F Fluorinated 29 ± 2 0 71 ± 2 UV Exposure 31 ± 2 2 ±2 67 ± 2

Infrared band assignments for polybutadiene are summarised in Table 5.

TABLE 5 Infrared assignments for polybutadiene film and new absorbenciesobserved following UV irradiation of plasma fluorinated polybutadiene.(No changes were observed upon CF₄ plasma fluorination). Frequency cm-1Intensity* Assignment 3300-3600 A† m, br —OH stretch 3075 M CH₂asymmetric stretch in —CH═CH₂; 1,2-addition 3005 B Sh CH stretch incis-CH═CH— ; 1 4-addition 2988 w, sh CH stretch in —CH═CH₂; 1,2-addition2975 Sh CH₂ symmetric stretch in —CH— CH₂; 1,2-addition 2917 Vs —CH₂symmetric stretch plus —CH— stretch 2845 S —CH₂ symmetric stretch 1790C† w, sh cyclic ester 1730 C† M aliphatic ester 1652 Sh —C═C— stretch,1,4-addition 1640 M —C═C-stretch in —C=CH₂; 1,2 addition 1453 M —CH₂—deformation; 1,2 addition 1438 Sh —CH₂— deformation; 1,4 addition 1419 M—CH₂— in plane deformation; 1,2-addition 1406 vw, sh —CH— in planedeformation in cis-CH═CH— ; 1,4- addition 1325-1350 W —CH2— wag1294-1320 W —CH₂— in plane rock 1238 vw, br —CH₂— twist 1180 D† M O—Hbend, principally primary alcohol 1080 W, br —CH₂— in plane rock of—CH=CH₂; 1,2 addition 995 S CH out of plane bending in —CH═CHz, 1,2addition 967 5 CH out of plane bending in trans —CH═CH— ; 1,4- addition911 Vs CH out of plane bending in —CH═CH₂ 727 W, br CH out of planebending in cis —CH═CH— ; 1,4- addition 681 W Unknown; 1,2-addition° *s =strong; m = medium; w = weak; v = very; sh = shoulder; br = broad †Thesefeatures only appear upon UV exposure

No new infrared absorption features were observed following CF₄ plasmafluorination of polybutadiene. This can be explained in terms of thesurface sensitivity of this analytical technique being poor intransmission mode of analysis (since only the outer most layer ofpolybutadiene has undergone plasma fluorination—as exemplified by XPSanalysis). Bulk oxidative crosslinking of these films during UVirradiation is evident on the basis of the observed attenuation of theCH stretch feature associated with the polybutadiene alkene bonds (B)and also the emergence of oxygenated groups (A, C, and D), FIG. 4 andTable 5. Corresponding water sessile drop contact angle measurementsconfirms the super-hydrophobic nature of plasma fluorinatedpolybutadiene surface, Table 6.

TABLE 6 Water contact angle measurements following UV irradiation of CF₄plasma fluorinated (60 W, 10 min)/236 nm thick polybutadiene film. UVContact Angle/° Exposure/mins Equilibrium Advancing Receding 0 174.9 ±0.4 173.1 ± 0.4 172.7 ± 0.5 20   173 ± 1.0 171.6 ± 0.5 170.8 ± 0.4 40  172 ± 1.2 171.4 ± 0.5 170.0 ± 1.0 60 170.3 ± 1.0 171.0 ± 0.7 169.0 ±0.7

The improvement in surface wettability observed following UV irradiationof the fluorinated surface can be correlated to oxygen incorporationinto the film, Tables 4 and 6.

(b) UV Patterning of Fluorinated Polybutadiene Films

In the case of UV photopatterning of the CF₄ plasma fluorinatedpolybutadiene film, AFM indicates a drop in height for exposed squareregions, FIG. 5. Immersion of these patterned films in toluene ortetrahydrofuran causes an exacerbation of the observed topography. Thiscan be due to either solvent swelling in the unexposed (non-crosslinked)regions or improved AFM tip-surface interactions.

(c) Copper Sulfate Salt and Polystyrene Microsphere Patterning

It is found that during exposure to steam, water droplets undergoselective condensation onto the UV irradiated square regions of thefluorinated polybutadiene film surface, FIG. 6. Analogous behaviour isalso observed in the case of a nebulized mist of aqueous Cu₂SO₄solution, giving rise to selective growth of salt crystals within thepatterned squares, FIG. 7. It is found that the actual crystal size canbe tailored by varying the mist exposure time.

In a similar fashion, exposure to a nebulized aqueous mist ofpolystyrene microspheres (either 0.61 μm or 9.1 μm diameter) producesarrays of agglomerated 0.61 μm beads, or isolated 9.1 μm beads in eachsquare (since for the latter, only one bead can physically occupy anindividual 14 μm^(i) diameter square), FIG. 8.

(d) Gold Patterning

No strong Raman absorbances are measured for the polybutadiene film.Raman spectroscopy of CF₄ plasma treated and UV cured polybutadiene filmfollowed by soaking in AuCl₃/ethylacetate (10 w/v %) solution and thenrinsing in methanol gives a distinct band structure between 24G-370cm⁻¹, attributable to AuCl₃ salt species, FIG. 9. Raman spectral mappingbased on this spectral region confirmed selective deposition of AuCl₃into the UV irradiated squares, FIG. 9. XPS analysis of AuCl₃ soakedfilms, before and after UV irradiation (no patterning), shows verylittle gold or chlorine content on either of the films. Raman imagestaken of UV exposed fluorinated films without the photomask indicatedthe absence of AuCl₃. This confirms the preference for surface energygradients to allow entrapment of the metal salt species.

Thus, from this example, CF₄ plasma modification of polybutadiene filmleads to fluorination in the outer surface region (i.e. the electricaldischarge penetration depth) whilst the underlying polybutadiene can besubsequently crosslinked. There are several different ways in which thelatter step can be undertaken: e.g. heat, UV or γ irradiation. In thecase of UV irradiation, oxygen incorporation into the film is consistentwith an oxidative cross-linking mechanism, which leads to acorresponding drop in water contact angle, FIG. 4 and Table 6. Thecorresponding surface roughness is not found to change markedly upon UVexposure (as also seen previously with thermal curing), thereby rulingout any observed change in water contact angle being just amanifestation of enhanced roughening. UV irradiation through amicron-scale copper grid produces a drop in height for the exposedregions, which is consistent with shrinkage of the sub-surface elastomerduring cross-linking. Soaking of these films in toluene and THF(solvents for polybutadiene) exacerbates the observed height difference,due to enhanced swelling of the underlying regions of uncuredpolybutadiene (although a perturbation in AF1VI tip-surface interactionscannot be ruled out). The possibility of polymer removal during solventimmersion is considered to be unlikely due to the thin cross-linked toplayer formed by VUV and ion bombardment during CF₄ plasma treatment.

Thus, the present invention allows many advantages to be obtained,firstly in the provision of surfaces which have improved liquidrepellence in comparison to conventional coatings, but still achievesdesirable durability characteristics. Furthermore the provision of theseimproved characteristics can be selectively applied to the surface toallow the substrate with said coating to be treated in a manner toimprove and/or define the usage of the same.

1-28. (canceled)
 29. A substrate comprising: a treated portion of thesubstrate defining a hydrophobic and/or oleophobic liquid repellantpattern; and an untreated portion of the substrate defining at least oneliquid collection area surrounded and defined by at least a portion ofthe liquid repellant pattern, wherein the at least one liquid collectionarea extends in two directions and a width of the at least one liquidcollection area in at least one direction is wider than the at least aportion of the liquid repellant pattern surrounding the at least oneliquid collection area.
 30. The substrate of claim 29, wherein theliquid repellant pattern is a grid pattern surrounding a plurality ofliquid collection areas such that adjacent liquid collection areas areseparated by a portion of the grid pattern.
 31. The substrate of claim29, wherein the treated portion of the substrate is fluorinated.
 32. Thesubstrate of claim 31, wherein the fluorinated portion comprises afluoropolymer.
 33. The substrate of claim 29, wherein the liquidrepellant pattern has increased hydrophobicity and/or oleophobicity ascompared to the at least one liquid collection area.
 34. The substrateof claim 29, wherein the liquid repellant pattern has a water contactangle greater than about 157°.
 35. A substrate comprising a treatedportion of the substrate defining hydrophobic and/or oleophobic liquidrepellant border that forms a perimeter around an untreated portion ofthe substrate defining at least one liquid collection area, wherein theat least one liquid collection area extends in two directions and awidth of the at least one liquid collection area in at least onedirection is wider than the liquid repellant border.
 36. The substrateof claim 35, wherein the liquid repellant border has increasedhydrophobicity and/or oleophobicity as compared to the hydrophobicityand oleophobicity of the at least one liquid collection area.
 37. Thesubstrate of claim 35, wherein the substrate comprises a fluorinatedportion defining the liquid repellant border.
 38. The substrate of claim37, wherein the fluorinated portion comprises a fluoropolymer.
 39. Thesubstrate of claim 35, wherein the liquid repellant border is a gridpattern forming a perimeter around a plurality of liquid collectionareas such that adjacent liquid collection areas are separated by aportion of the grid pattern.
 40. An apparatus, comprising: a substratedefining a surface; a liquid repellant layer disposed on the surface ofthe substrate and defining a hydrophobic and/or oleophobic surface, theliquid repellant layer comprising a plurality of linear sectionsintersecting to define at least one bounded area; and a liquidcollection area defined by a portion of the surface of the substratethat is disposed within the at least one bounded area of the liquidrepellant layer.
 41. The apparatus of claim 40, wherein the surface ofthe substrate is a horizontal surface.
 42. The apparatus of claim 40,wherein the liquid repellent layer comprises a fluoropolymer.
 43. Theapparatus of claim 40, wherein the plurality of linear sections havesubstantially the same length.
 44. The apparatus of claim 40, whereinrespective pairs of the plurality of linear sections defining oppositeends of the at least one bounded area have substantially the samelength.
 45. The apparatus of claim 40, wherein the plurality of linearsections have substantially the same width.
 46. The apparatus of claim40, wherein the plurality of linear sections have substantially the samedimensions.
 47. The apparatus of claim 40, wherein each of the pluralityof linear sections has a length that is greater than a width of thelinear section.
 48. The apparatus of claim 40, wherein the at least onebounded area is polygon shaped.
 49. An apparatus, comprising: asubstrate; a liquid repellant layer coated on a surface of the substrateand defining a hydrophobic and/or oleophobic surface, the liquidrepellant layer comprising a plurality of linear sections intersectingto define at least one bounded, uncoated portion of the surface of thesubstrate, wherein the at least one bounded uncoated portion of thesurface of the substrate defines a liquid collection area.
 50. Theapparatus of claim 49, wherein the surface of the substrate is ahorizontal surface.
 51. The apparatus of claim 49, wherein the liquidrepellent layer comprises a fluoropolymer.
 52. The apparatus of claim49, wherein the plurality of linear sections have substantially the samelength.
 53. The apparatus of claim 49, wherein respective pairs of theplurality of linear sections defining opposite ends of the at least onebounded uncoated portion have substantially the same length.
 54. Theapparatus of claim 49, wherein the plurality of linear sections havesubstantially the same width.
 55. The apparatus of claim 49, wherein theplurality of linear sections have substantially the same dimensions. 56.The apparatus of claim 49, wherein each of the plurality of linearsections has a length that is greater than a width of the linearsection.
 57. The apparatus of claim 49, wherein the at least one boundeduncoated portion is polygon shaped.
 58. An apparatus, comprising: asubstrate; a liquid repellant layer coated on a surface of the substrateand defining a hydrophobic and/or oleophobic surface, the liquidrepellant layer comprising a plurality of linear sections intersectingto form at least one liquid repellent perimeter; and a liquid collectionarea defined by a portion of the surface of the substrate that isdisposed within the at least one liquid repellent perimeter.
 59. Theapparatus of claim 58, wherein the surface of the substrate is ahorizontal surface.
 60. The apparatus of claim 58, wherein the liquidrepellent layer comprises a fluoropolymer.
 61. The apparatus of claim58, wherein the plurality of linear sections have substantially the samelength.
 62. The apparatus of claim 58, wherein respective pairs of theplurality of linear sections defining opposite ends of the at least oneliquid repellent perimeter have substantially the same length.
 63. Theapparatus of claim 58, wherein the plurality of linear sections havesubstantially the same width.
 64. The apparatus of claim 58, wherein theplurality of linear sections have substantially the same dimensions. 65.The apparatus of claim 58, wherein each of the plurality of linearsections has a length that is greater than a width of the linearsection.
 66. A method of forming a liquid collection area on a surface,comprising selectively fluorinating the surface to create a liquidrepellent pattern, wherein at least a portion of the liquid repellantpattern surrounds and defines at least one liquid collection area havinglower liquid repellence than the liquid repellent pattern, and whereinthe at least one liquid collection area extends in two directions and awidth of the at least one liquid collection area in at least onedirection is wider than the at least a portion of the liquid repellantpattern surrounding the at least one liquid collection area.
 67. Themethod of claim 66, wherein selectively fluorinating a portion of thesurface comprises applying a polymer material to the surface configuredin the liquid repellent pattern, and fluorinating the polymer materialand/or curing the polymer material.
 68. The method of claim 67, whereinfluorination of the polymer material increases the hydrophobicity and/oroleophobicity of the polymer material.
 69. The method of claim 67,wherein the polymer material includes unsaturated bonds.
 70. The methodof claim 66, wherein the liquid repellent pattern is hydrophobic and/oroleophobic.
 71. The method of claim 66, wherein the liquid repellentpattern has increased hydrophobicity and oleophobicity as compared tothe hydrophobicity and oleophobicity of the liquid collection area. 72.The method of claim 66, wherein the liquid repellent pattern is formedas a grid pattern surrounding a plurality of liquid collection areassuch that adjacent liquid collection areas are separated by a portion ofthe grid pattern.
 73. The method of claim 66, wherein the liquidcollection area is defined by an untreated portion of the surfacesurrounded by the liquid repellent pattern.
 74. The method of claim 66,wherein the liquid repellent pattern has a water contact angle greaterthan about 157°.
 75. The method of claim 66, wherein the surface ishorizontal.
 76. A method of forming a liquid repellent border,comprising selectively fluorinating a surface of a substrate to create aliquid repellent border that forms a perimeter around at least oneliquid collection area having lower liquid repellence than the liquidrepellent border, wherein the at least one liquid collection areaextends in two directions and a width of the at least one liquidcollection area in at least one direction is wider than the at least aportion of the liquid repellant border surrounding the at least oneliquid collection area.
 77. The method of claim 76, wherein selectivelyfluorinating a portion of the surface comprises applying a polymermaterial to the surface configured in the liquid repellent border, andfluorinating the polymer material and/or curing the polymer material.78. The method of claim 77, wherein fluorination of the polymer materialincreases the hydrophobicity and/or oleophobicity of the polymermaterial.
 79. The method of claim 77, wherein the polymer materialincludes unsaturated bonds.
 80. The method of claim 76, wherein theliquid repellent border is hydrophobic and/or oleophobic.
 81. The methodof claim 76, wherein the liquid repellent border has increasedhydrophobicity and oleophobicity as compared to the hydrophobicity andoleophobicity of the liquid collection area.
 82. The method of claim 76,wherein the liquid repellent border is formed as a grid pattern forminga perimeter around a plurality of liquid collection areas such thatadjacent liquid collection areas are separated by a portion of the gridpattern.
 83. The method of claim 76, wherein the liquid collection areais defined by an untreated portion of the surface of the substratesurrounded by the liquid repellent border.
 84. The method of claim 76,wherein the liquid repellent pattern has a water contact angle greaterthan about 157°.
 85. The method of claim 76, wherein the surface of thesubstrate is horizontal.
 86. A method of forming a liquid repellentpattern, comprising selectively fluorinating a surface of a substrate tocreate a liquid repellent layer comprising a plurality of linearsections intersecting to surround and define at least one boundeduntreated portion of the surface of the substrate, wherein the at leastone bounded untreated portion of the surface of the substrate defines aliquid collection area.
 87. The method of claim 86, wherein the surfaceof the substrate is horizontal.
 88. The method of claim 86, wherein theplurality of linear sections define a liquid repellent perimetersurrounding the liquid collection area.
 89. The method of claim 86,wherein the liquid repellent layer has increased hydrophobicity andoleophobicity as compared to the hydrophobicity and oleophobicity of theliquid collection area.
 90. The method of claim 86, wherein theplurality of linear sections have substantially the same length.
 91. Themethod of claim 86, wherein respective pairs of the plurality of linearsections defining opposite ends of the at least one bounded untreatedportion have substantially the same length.
 92. The method of claim 86,wherein the plurality of linear sections have substantially the samewidth.
 93. The method of claim 86, wherein the plurality of linearsections have substantially the same dimensions.
 94. The method of claim86, wherein each of the plurality of linear sections has a length thatis greater than a width of the linear section.
 95. The method of claim86, wherein the at least one bounded untreated portion is polygonshaped.
 96. A substrate having at least one surface to which a coatingis applied, said coating having at least an outer layer of polymermaterial and at least a portion of said polymer material is fluorinatedto provide the same with improved liquid repellent and durabilitycharacteristics.
 97. The substrate of claim 96, wherein the selectiveportions of the polymer material which are not fluorinated and/or curedcan act as collecting areas for liquid.
 98. The substrate of claim 96,wherein the substrate has defined therein a number of spaced liquidcollection areas, each separated by areas of increased liquidrepellence.
 99. The substrate of claim 98, wherein the spaced liquidcollection areas are surrounded by the areas of increased liquidrepellence.
 100. The substrate of claim 98, wherein the areas ofincreased liquid repellence form a grid pattern surrounding the spacedliquid collection areas such that adjacent liquid collection areas areseparated by a portion of the grid pattern.
 101. The substrate of claim96, wherein the fluorinated and/or cured polymer material is hydrophobicand/or oleophobic.
 102. The substrate of claim 96, wherein the polymermaterial is cured, wherein the fluorinated and cured polymer materialhas a water contract angle greater than about 157°.
 103. The substrateof claim 96, wherein the at least one surface is a horizontal surface.